System and method for determining slurry sand concentration and continuous calibration of metering mechanisms for transferring same

ABSTRACT

In accordance with presently disclosed embodiments, systems and methods for determining the amount of bulk material being choke-fed into an inlet of a blender from one or more bulk material containers placed on a support structure are disclosed. The system includes sensors placed on the support structure beneath the one or more containers for determining the amount of bulk material contained within the container at any given time. By monitoring the change in the mass of the material in the containers overtime the amount of material being fed into the blender can be determined. The material is metered into a mixer within the blender using a metering mechanism, such as a sand screw, which supplies a fixed capacity of bulk material into the blender. The ability to precisely measure the amount of bulk material being choke-fed into the blender enables operators to calibrate the sand screw continuously.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation of U.S. patent applicationSer. No. 15/770,408 filed Apr. 23, 2018, which is a U.S. National StageApplication of International Application No. PCT/US2015/067520 filedDec. 22, 2015, both of which are incorporated herein by reference intheir entirety for all purposes.

TECHNICAL FIELD

The present disclosure relates generally to transferring bulk materialsfor use in downhole treatment fluids, and more particularly, to accuratemeasurement of bulk materials during operation at a well site.

BACKGROUND

During the drilling and completion of oil and gas wells, variouswellbore treating fluids are used for a number of purposes. For example,high viscosity gels are used to create fractures in oil and gas bearingformations to increase production. High viscosity and high density gelsare also used to maintain positive hydrostatic pressure in the wellwhile limiting flow of well fluids into earth formations duringinstallation of completion equipment. High viscosity fluids are used toflow sand into wells during gravel packing operations. Hydraulicfracturing operations may use a wide range of fluid viscosities andcharacteristics also to transport proppant into natural and inducedfactures in the petroleum bearing formation. The wellbore treatingfluids are normally produced by mixing dry powder and/or granularmaterials and agents with water at the well site as they are needed forthe particular treatment. Systems for metering and mixing the variousmaterials are normally portable, e.g., skid- or truck-mounted, sincethey are needed for only short periods of time at a well site.

The powder or granular treating material is normally transported to awell site in a commercial or common carrier tank truck. Once the tanktruck and mixing system are at the well site, the powder material (bulkmaterial) must be transferred or conveyed from the tank truck into asupply tank for metering into a blender as needed. The bulk material isusually transferred from the tank truck pneumatically. Morespecifically, the bulk material is blown pneumatically from the tanktruck into an on-location storage/delivery system (e.g., silo). Thestorage/delivery system may then deliver the bulk material onto aconveyor or into a hopper, which meters the bulk material by means of anauger screw into a blender tub.

Recent developments in bulk material handling operations involve the useof portable containers for transporting dry material about a welllocation. The containers can be brought in on trucks, unloaded, storedon location, and manipulated about the well site when the material isneeded. The containers are generally easier to manipulate on locationthan a large supply tank trailer. The containers are eventually emptiedby dumping the contents thereof onto a mechanical conveying system(e.g., conveyor belt, auger, bucket lift, etc.). The conveying systemthen moves the bulk material in a metered fashion to a desireddestination at the well site.

An important aspect of delivering bulk dry material and liquid materialsused in forming sand slurries and other downhole treatment andcompletion fluids is the accurate measurement of the amount of bulk dryand liquid materials used in the production of such slurries and fluids.Accurate measure is important for a number of reasons other than thephysical properties of the slurry, an important one of which being foraccounting and billing purposes. In today's downhole operations, thereare a wide variety of measurement methods used, each having its ownlevel of accuracy and unique sources of error.

Fluid additive tanks are most commonly measured volumetrically with adepth stick or strap. Each container has a unique measurement strap thatis calibrated to the varying cross-sectional area of the container. Thismethod is prone to a high degree of subjectivity due to the fact thatthe operator is reading the depth measured on the strap. This methodalso generally does not account for changes in the fluid volume due tothermal expansion or contraction as may occur with temperature changes.As the fluids are drawn from the bulk tanks it is passed throughexpensive, generally highly accurate, coriolis flow meters before beingmixed with the treatment slurry. However, any air entrainment in thefluid significantly impacts the accuracy of the coriolis measurements.As a result, great efforts in personnel time are taken to reconcilediscrepancies caused by such inaccuracies.

Dry additives (e.g., sand, proppant, gel, diverters, etc.) are generallymeasured using auger screws. The dry material is typically delivered toa hopper and metered/conveyed from the hopper to the mixer with an augerscrew. The volume or mass flow rate of dry material is determined fromthe rotational speed, or revolutions per minute (RPM) of the screw and acalibration factor (weight or volume of material moved per revolution ofthe auger, which may be measured in lbs/rev or via a drive signalmeasured in lb/mA) for that particular material, screw size, and screworientation. For example, the sand screws are placed at an angle to liftthe sand from the hopper to the top of the mixing tub. Each sand type(100 mesh, 20/40 mesh, resin coated, etc.) will have different transferefficiencies through the screw, and require a different calibrationcurve. However, the calibration factor may vary if additional humidityis present in the sand, or if liquid additives/coatings are being mulledinto the sand in the screw, such as is the case with the SandWedge® orFinesWedge® systems, provided by Halliburton, the assignee of thepresent application. The depth of material covering the auger inlet anddimensional changes caused by wear also affect the calibration curve. Inaddition, the testing required to calibrate the screws for each materialis not trivial. Accordingly, only a small number of the various sandtypes have measured calibration curves, and calibration factors areoften assumed by the blender operators.

Due to the inaccuracies in the these measures, many customers of servicecompanies require that additional measurements be taken to determine, inparticular, the sand concentration of the treatment slurry beingdelivered to the wellhead. The sand concentration is indirectly measuredusing a radioactive densometer placed downstream and proximate an outletof the mixing tub. If the base fluid density is accurately known, thenthe bulk density measurement from the densometer can be reliably used toprovide the sand concentration in lbm sand per gallon of fluid. However,the exact base fluid density is often unknown due to the variety ofwater sources that are used, the variation in salt concentration in thewater through the job, and the various additives being introduced to thefluid before the densometer.

Accordingly, a direct and precise measurement of the bulk material beingadded to the mixing tub prior to mixing with the liquid additives isdesired.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and itsfeatures and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a schematic block diagram of a system for delivering bulkmaterial from a container disposed on a portable support structure intoa blender, in accordance with an embodiment of the present disclosure;

FIG. 2 is a perspective view of a portable support structure used tosupport and weigh a plurality of containers of bulk material, inaccordance with an embodiment of the present disclosure;

FIG. 3 is a schematic diagram of the mechanisms for delivering bulkmaterial and clean fluids into a mixer in accordance with the presentdisclosure; and

FIG. 4 is a schematic block diagram of an embodiment of an electronicscontrol system that measures the amount of dry bulk material beingchoke-fed into the blender and calibrates a sand screw used to meter thedry bulk material into the mixing tub of the blender in accordance withan embodiment of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure are described indetail herein. In the interest of clarity, not all features of an actualimplementation are described in this specification. It will of course beappreciated that in the development of any such actual embodiment,numerous implementation specific decisions must be made to achievedevelopers' specific goals, such as compliance with system related andbusiness related constraints, which will vary from one implementation toanother. Moreover, it will be appreciated that such a development effortmight be complex and time consuming, but would nevertheless be a routineundertaking for those of ordinary skill in the art having the benefit ofthe present disclosure. Furthermore, in no way should the followingexamples be read to limit, or define, the scope of the disclosure.

The method according to the present disclosure will now be described.Electronic load cells (scales) are placed under each bulk materialcontainer (dry or liquid) so that the mass of the material in thecontainer can be directly measured continuously. By observing the changein total mass over time, the mass flow rate may be accurately obtained,irrespective of air entrainment in the fluid or along the flow lines orchanges in density due to thermal expansion. The present disclosure'sapproach of using a mass measurement will eliminate the need forexpensive micro-motion flowmeters, which will result in a capital costsavings. Also, this will minimize any discrepancy between volumemeasurements of the material in the container, liquid volume flow ratesto the blender, and the amount of product to be billed to the customer.

The present disclosure also provides for placing the portable sandcontainers (e.g., on the containers used in the Xpress™ Sand DeliverySystem provided by Halliburton, the assignee of the present application)on load cells. The mass of proppant in each container can becontinuously measured to produce the mass flow rate of proppant to theblender. Even though the proppant is generally first delivered to theblender hopper before being lifted/metered by the sand screws to themixing tub, under steady operation, the choked gravity feed between theXpress™ Sand container and the hopper will require that the volume ofsand in the hopper remain constant. So the mass flow rate leaving thecontainer will be equal to the mass flow rate being passed through thesand screws. Due to this configuration, the calibration factors for thesand screws can be regularly updated as the sand properties and sandscrew RPM vary throughout the job. A similar process can be used for theother dry additive measurements, transfer and calibrated mass flowcontrol.

The reason for updating the sand screw calibration factors is that thesecalibration factors are used in the blender control algorithms to setthe screw speeds to achieve the desired product flow rate. Details ofthese automatic control systems for the sand screws can be found in U.S.Pat. Nos. 4,779,186 and 5,335,166. Thus, rather than using the postblender bulk density measurement from the densometer to provide thefeedback to the control system to automatically adjust the sand screwspeed to achieve the expected bulk density of the slurry for the assumedbase fluid density and desired sand concentration, the control systemcan directly regulate the screw speed to achieve the desired sand massflow rate. In order to provide an accurate calibration measure, the sandscrew speed must be held constant for a given amount of time to ensuresteady operation. As such, the control system for the screws will needto be modified to periodically not automatically update the screw speedto achieve the desired/programmed post blender sand concentration andallow for an accurate calibration run.

Alternatively, a control algorithm for the sand screws, or other drymaterial transfer, may be implemented that does not require acalibration factor. Such a control algorithm may take as inputs themeasured mass flow rate leaving the container, the desired mass flowrate, and the current sand screw RPM. The output of the controlalgorithm may be the change in sand screw RPM required to achieve thedesired mass flow rate. The necessary change of RPM may be calculatedusing various methods, depending on the type of feedback control methodbeing applied (e.g., proportional control,proportional-integral-derivative control, etc.). With the mass flow ratebeing measured for each material additive source making up the treatmentslurry, the total mass flow rate of additives is directly known. Inorder to extract the sand concentrations per volume of clean fluid, anadditional measurement is needed, namely the volume flow rate from theclean water source. By measuring the volume flow rate of the clean watersource, and comparing to the sand mass flow rate, the sand concentrationper volume of clean fluid can be directly calculated as the ratio ofthese two measurements. This is the primary value required to meettypical job designs in the field.

In another aspect of the present disclosure, the control system monitorschanges in the calibration factor over time, such that a decreasingtrend in the calibration factor generally indicates that the meteringmechanism needs replacement. The control system can be programmed towarn the operator to make such a change.

Turning now to the drawings, the system in accordance with presentdisclosure will now be described. FIG. 1 is a block diagram of a bulkmaterial handling system 10 in accordance with the present disclosure.The system 10 includes a container 12 elevated on a portable supportstructure 14 and holding a quantity of bulk material (e.g., solid orliquid treating material). The portable support structure 14 may includea frame 16 for receiving and holding the container 12 and a gravity feedoutlet 18 for directing bulk material away from the container 12. Theoutlet 18 may be coupled to and extending from the frame 16. The outlet18 may utilize a gravity feed to provide a controlled, i.e., metered,flow of bulk material from the container 12 to a blender unit 20.

As illustrated, the blender unit 20 may include a hopper 22 and a mixingtub or mixer 24. The blender unit 20 may also include a meteringmechanism 26 for providing a controlled, i.e., metered, flow of bulkmaterial from the hopper 22 to the mixer 24. An exemplary meteringmechanism 26 is a sand screw, which has the shape of an auger andpermits discrete quantities of bulk material to be conveyed over a unitof time.

Water and other additives may be supplied to the mixer 24 through afluid inlet flow line 28. As those of ordinary skill in the art willappreciate, the fluid inlet flow line 28 may comprise more than the oneinput flow line illustrated in FIG. 1. A flow meter 29 (shown in FIG. 3)may optionally be installed in the fluid inlet flow line 28 formeasuring the flow rate of the fluid being injected into the mixer 24.It is connected either via a wired connection or wirelessly to thecontroller 90, as described in further detail below. The bulk materialand water may be mixed in the mixer 24 to produce (at an outlet flowline 30) a fracing fluid, a mixture combining multiple types ofproppant, proppant/dry-gel particulate mixture, sand/sand-divertingagents mixture, cement slurry, drilling mud, a mortar or concretemixture, or any other fluid mixture for use on location. The outlet flowline 30 may be coupled to a pump for conveying the treating fluid to adesired location (e.g., a hydrocarbon recovery well) for a treatingprocess. A densometer 31 (shown in FIG. 3) may optionally be installedin the outline flow line 30 to measure the sand concentration exitingthe mixer 24. The densometer 31 is connected to the controller 90 eithervia a wired connection or wirelessly, as described in further detailbelow.

It should be noted that the disclosed container 12 may be utilized toprovide bulk material for use in a variety of treating processes. Forexample, the disclosed systems and methods may be utilized to provideproppant materials into fracture treatments performed on a hydrocarbonrecovery well. In other embodiments, the disclosed techniques may beused to provide other materials (e.g., non-proppant) for diversions,conductor-frac applications, cement mixing, drilling mud mixing, andother fluid mixing applications.

As illustrated, the container 12 may be elevated above an outletlocation via the frame 16. The support structure 14 is designed toelevate the container 12 above the level of the blender inlet (e.g.,blender hopper 22 and/or mixing tub 24) to allow the bulk material togravity feed from the container 12 to the blender unit 20. This way, thecontainer 12 is able to sit on the frame 16 of the support structure 14and output bulk material directly into the blender unit 20 via thegravity feed outlet 18 of the support structure 14.

Although shown as supporting a single container 12, other embodiments ofthe frame 16 may be configured to support multiple containers 12. Theexact number of containers 12 that the support structure 14 can hold maydepend on a combination of factors such as, for example, the volume,width, and weight of the containers 12 to be disposed thereon.

In any case, the container(s) 12 may be completely separable andtransportable from the frame 16, such that any container 12 may beselectively removed from the frame 16 and replaced with anothercontainer 12. That way, once the bulk material from the container 12runs low or empties, a new container 12 may be placed on the frame 16 tomaintain a steady flow of bulk material to an outlet location. In someinstances, the container 12 may be closed before being completelyemptied, removed from the frame 16, and replaced by a container 12holding a different type of bulk material to be provided to the outletlocation.

A portable bulk storage system 32 may be provided at the site forstoring one or more additional containers 12 of bulk material to bepositioned on the frame 16 of the support structure 14. The bulkmaterial containers 12 may be transported to the desired location on atransportation unit (e.g., truck). The bulk storage system 32 may be thetransportation unit itself or may be a skid, a pallet, or some otherholding area. One or more containers 12 of bulk material may betransferred from the storage system 32 onto the support structure 14, asindicated by arrow 34. This transfer may be performed by lifting thecontainer 12 via a hoisting mechanism, such as a forklift, a crane, or aspecially designed container management device.

When the one or more containers 12 are positioned on the supportstructure 14, discharge gates on one or more of the containers 12 may beopened, allowing bulk material to flow from the containers 12 into theoutlet 18 of the support structure 14. The outlet 18 may then route theflow of bulk material directly into a blender inlet (e.g., into thehopper 22 or mixer 24) of the blender unit 20.

After one or more of the containers 12 on the support structure 14 areemptied, the empty container(s) 12 may be removed from the supportstructure 14 via a hoisting mechanism. In some embodiments, the one ormore empty containers 12 may be positioned on another bulk storagesystem 32 (e.g., a transportation unit, a skid, a pallet, or some otherholding area) until they can be removed from the site and/or refilled.In other embodiments, the one or more empty containers 12 may bepositioned directly onto a transportation unit for transporting theempty containers 12 away from the site. It should be noted that the sametransportation unit used to provide one or more filled containers 12 tothe location may then be utilized to remove one or more empty containers12 from the site.

FIG. 2 illustrates an embodiment of the support structure 14 that may bedesigned to receive multiple containers. Specifically, the supportstructure 14 includes a frame 16 sized to receive and support up tothree portable containers. The frame 16 may include several beamsconnected together (e.g., via welds, rivets or bolts) to form acontinuous group of cubic or rectangular shaped supports 50 coupled endto end. For example, in the illustrated embodiment the frame 16generally includes one continuous, elongated rectangular body brokeninto three distinct cubic/rectangular supports 50A, 50B, and 50C. Eachcubic/rectangular support 50 may be used to support a single container.The frame 16 may include additional beams that function as trusses tohelp support the weight of the filled containers disposed on the frame16. Other shapes, layouts, and constructions of the frame 16 may be usedin other embodiments. In addition, other embodiments of the supportstructure 14 may include a frame 16 sized to receive other numbers(e.g., 1, 2, 4, 5, 6, 7, or more) portable containers. As those ofordinary skill in the art will appreciate, the exact number ofcontainers on the frame 14 is not critical to the present disclosure.

As illustrated, the support structure 14 may be equipped with aplurality of container mounts 52 disposed on top of the frame 16 forpositioning and holding the containers on the frame 16. The containersmay include complementary engagement features designed to interface withthe mounts 52, thus enabling a precise placement of the containers intodesired locations on the frame 16. In the illustrated embodiment, themounts 52 are generally disposed at the corners on the upper face ofeach cubic/rectangular support 50. However, other placements of themounts 52 along the upper surface of the support structure 16 may beutilized in other embodiments.

Beneath each mount 52 is disposed a micro-scale load cell 53. Exemplarymicro-scale load cells 53, include, but are not limited to straingauges, piezoelectric gauges, hydraulic or pneumatic gauges, or similardevices. Each micro-scale load-cell 53 is connected via a wired orwireless connection to a controller 90, as shown in FIG. 4. Eachmicro-scale load cell 53 communicates a signal indicative of the weightof the container and its contents sensed by the load cell. Withknowledge of the mass of each container, an algorithm stored in thememory 98 and executed by the processor 96, can determine the mass ofbulk material in each of the containers 12. Furthermore, by monitoringthe change in the weight of the bulk material being fed from thecontainers into the blender 20 per unit of time the flow rate of thebulk material into the blender can be determined. Since there is no lossof the bulk material being delivered to the blender 20 given the closednature of the system and the fixed capacity of the sand screw, the flowrate determined using this technique results in a highly accuratedetermination of the amount of bulk material being utilized. This inturn allows for accurate accounting and thus accurate billing for theamount of bulk product being consumed.

The support structure 14 may also include one or more actuators 54designed to aid in actuation of a discharge gate of the one or morecontainers disposed on the frame 16. In the illustrated embodiment, theactuators 54 may be rotary actuators designed to rotate into engagementwith a discharge gate of a container to transition the gate between aclosed position and an open position. In other embodiments, theactuators 54 may be linear actuators designed to interface with thegates of the containers to selectively open and close the gates. In someembodiments, the actuators 54 may include a set of two actuators(disposed on opposite sides of the frame 16) for actuating the dischargegate of a single container disposed on the frame 16. In such anarrangement, one of the actuators 54 may transition the gate from closedto open, while the opposite actuator 54 may transition the gate fromopen to closed.

As described above, the support structure 14 may include several gravityfeed outlets 18 for routing bulk material directly from one or morecontainers disposed on the frame 16 into a blender inlet. The blenderinlet may be a blender hopper (e.g., hopper 22 of FIG. 1) used toprovide bulk material to a metering system that meters the bulk materialinto a mixer. In another embodiment, the blender inlet may be the sandscrew or other similar metering mechanism 26 of FIG. 1. Otherembodiments may utilize other types of blender inlets for receiving thebulk material from the containers disposed on the support structure 14.The blender 20 of the present disclosure, however, contemplates use of asand screw 26 or other similar metering mechanism (such as a meteringgate or valve positioned above the mixer) 26 for metering the bulkmaterial into the mixer 24. A close up of the blender 20 employing ametering mechanism 26 such as a sand screw in connection with thepresent disclosure can be seen in FIG. 3. An electric motor 27 whichcontrols the rotation of the sand screw is attached via gears to themain shaft of the sand screw onto which is affixed an auger. Theelectric motor 27 is connected to the controller 90 via a wiredconnection or wirelessly as further explained below. Alternatively, ahydraulic motor could also be used for driving the auger.

The gravity feed outlets 18A, 18B, and 18C may be used to deliver a flowof bulk material to the blender hopper 22 (or other blender inlet) fromeach of three respective containers disposed on the frame 16. In someembodiments, the support structure 14 may also include individualhoppers 60A, 60B, and 60C at the top of the frame 16 for funneling bulkmaterial from the discharge gate of the corresponding containers intothe gravity feed outlets 18A, 18B, and 18C, respectively.

The gravity feed outlets 18A, 18B, and 18C may be chutes positioned sothat the upper end of each chute is disposed beneath a discharge gate ofa corresponding container (or one of the hoppers 60) on the frame 16.The gravity feed outlets 18 may be positioned such that the lower end ofeach chute is disposed fully within the blender hopper 22. This allowsthe gravity feed outlets 18 to provide bulk material from all of thecontainers positioned on the frame 16 into the same blender inlet (e.g.,blender hopper 22) at the same time. The outlets 18 are able to providea gravity feed where an angle of repose of the bulk material exiting thechutes is able to choke the flow of bulk material through the chutes. Asbulk material is metered from the blender hopper 22 into another portionof the blender (e.g., mixer), additional bulk material is able to flowvia gravity into the hopper 22 directly from the one or more outlets 18.In embodiments where the gravity feed outlets 18 are positioned to routebulk material directly from the containers into an inlet of the mixer ofthe blender unit, the outlets 18 and/or the blender inlet may feature ametering gate/valve used to regulate the amount of bulk materialprovided into the mixer (e.g., instead of separate sand screws)

The disclosed gravity feed outlets 18 provide a more controlled outputof bulk material to the blender inlet (e.g., blender hopper 22) thanwould be available through the use of mechanical conveying systems todrop bulk material into the hopper. In addition, the choke feed of bulkmaterial through the outlets 18 and into the blender inlet may reduce anamount of dust generated at a well site, as compared to existingpneumatic or mechanical conveying systems. Further, the gravity feedoutlets 18 are able to route the bulk material directly into the blenderinlet from the containers without the use of pneumatic or mechanicalconveyance equipment operating on auxiliary power. This makes theprocess of moving the bulk material more efficient than would bepossible using a separate pneumatic or mechanical conveyor between thecontainers and the blender. Finally, use of the gravity feed/choke-feedoutlets 18 allows for a fixed capacity of bulk material to be deliveredinto the blender inlet.

Having discussed the mechanical components that make up system fordetermining the amount of bulk material being fed into a blender 20, amore detailed discussion of various electronics and controls that may beused within or communicatively coupled to the support structure 14 willbe provided. FIG. 4 is a block diagram illustrating the variouselectronic and control components that may be used throughout a wellsite with the disclosed portable support structure 14.

The portable support structure 14 may include a number of electroniccomponents, and these components may be communicatively coupled (e.g.,via a wired connection or wirelessly) to one or more controllers 90(e.g., automated control system) at the well site. For purposes of thepresent disclosure, the plurality of load cells 53 is connected to thecontroller. Furthermore, the fluid flow meter 29 is also connected tocontroller. The densometer 31 may optionally be connected to thecontroller. Also, the sand screw motor 27 is connected to the controller90. In the alternative embodiment where a hydraulic motor is used, thecontroller 90 would be connected to a hydraulic pump or valve that wouldcontrol the flow rate of fluid to the hydraulic motor. The controlsystem 90 may be communicatively coupled to several other well sitecomponents including, but not limited to, the blender unit 20, theactuators 54, and various other sensors 107.

The control system 90 utilizes at least a processor component 96 and amemory component 98 to monitor and/or control various operations andbulk material inventory at the well site and perform other calculations.For example, one or more processor components 96 may be designed toexecute instructions encoded into the one or more memory components 98.Upon executing these instructions, the processors 96 may execute one ormore algorithms to determine the amount of bulk material flowing intothe blender 20 from the one or more containers 12. They may alsodetermine the sand concentration exiting the mixer 24 using the weightmeasurements communicated from the load cells 53 and the fluid flow rateinformation communicated from the flow meter(s) 29. This information canbe compared to the sand concentration measured by the densometer 31.Furthermore, the densometer 31 measurements can be used to indirectlydetermine the amount of bulk material entering into the mixer 24 andcompared against the calculations made by the processor 96 using thesignals and measurements made by the load cells 53. Any discrepanciescan be used to alter the calibration factor for the sand screw 26. Theprocessor 96 can also control the sand screw speed via signals sent tothe electric motor 27 (or alternatively to a hydraulic pump or valvecontrolling fluid flow to a hydraulic motor). The amount of bulkmaterial contained within the containers 12 as determined using themicro-scale load cells 53 can also be compared to the weight ticketsupplied from the load station where the containers 12 were filled.Furthermore, the calibration factor of the sand screw can becontinuously updated based on the measurements obtained from themicro-scale load cells independent of any measurements taken from thedensometer 31. The calibration values could be monitored over time todetermine condition or amount of wear on the auger, the lbs/rev outputwill decrease with wear.

Furthermore, the controller 90 can be used for controlling passivelogging of certain operations at the well site, as well as the amount,type, and location of bulk materials at the well site. In someembodiments, the one or more processors 96 may execute instructions forcontrolling operations of certain well site components (e.g., supportstructure electronics, blender unit 20, hoisting mechanism 92, etc.).This may help to control transportation and placement of the supportstructure 14 relative to the blender inlet, as well as bulk materialtransfer at the well site. For example, the processors 96 may outputsignals at a user interface 99 for instructing operators to remove anempty container from the support structure 14 and replace the containerwith a new container holding a certain type of bulk material needed forthe well treatment. Other types of instructions for inventorycontrol/monitoring may be provided through the disclosed systems.

As shown, the support structure 14 itself may include a number ofelectronic components such as, for example, the automated actuators 54described above with reference to FIG. 2. These actuators 54 may becontrolled to open and/or close a discharge gate of one or morecontainers elevated on the support structure 14.

Other sensors 107 may be present throughout the support structure 14 formonitoring other operations in the delivery of the bulk material andfluids to the mixer 24 and the discharge of the sand concentration orother product of the mixer 24 out of the mixer and downhole.

The controller 90, the support structure electronics, or both, mayutilize power from an external power source 108, as shown. In otherembodiments, the support structure 14 may include its own power source108 for operating the onboard electronics and sensors.

As mentioned above, the controller 90 may be communicatively coupled tovarious other sensors 94 disposed about the well site. In someembodiments, these sensors 94 may include one or more load cells or binfull switches for tracking a level of bulk material in a portablecontainer and indicating whether the container is empty, full, orpartially full. Such sensors 94 may be used for any given container, theblender hopper, a silo (not shown), or any other component at the wellsite. In addition, in some embodiments the sensors 94 may include RFIDtags used to provide an indication of the particle size, bulk volume,weight, type, material, and/or supplier of the bulk material disposed ina certain container. In such instances, the controller 90 may becommunicatively coupled to an RFID reader disposed in proximity to thecontainers being moved about the well site.

Although the present disclosure and its advantages have been describedin detail, it should be understood that various changes, substitutionsand alterations can be made herein without departing from the spirit andscope of the disclosure as defined by the following claims.

The following are non-limiting, specific embodiments in accordance withthe present disclosure:

A first embodiment, which is a system, comprising a support structurefor holding at least one portable container of bulk material at aposition proximate a blender inlet, wherein the support structurecomprises: a frame for receiving and holding the at least one portablecontainer thereon; wherein the portable container is supported on theframe such that the portable container is selectively removable from theframe and replaceable by another portable container; and choke-feedoutlet coupled to the frame for routing the bulk material from the atleast one portable container directly into the blender inlet; at leastone sensor disposed in a position to sense an amount of bulk material inthe at least one portable container; a metering mechanism disposed atthe blender inlet; and a controller in communication with the at leastone sensor programmed to determine a rate of bulk material being routedinto the blender inlet and through the metering mechanism, wherein thecontroller is programmed to adjust its control of the metering mechanismbased on the rate of bulk material being fed into the blender inlet asmeasured by the at least one sensor.

A twelfth embodiment, which is a method, comprising receiving andholding one or more portable containers of bulk material onto a frame ofa support structure disposed proximate a blender inlet; sensing anamount of bulk material in the one or more portable containers via atleast one sensor; routing bulk material from the one or more portablecontainers directly into the blender inlet via a choke-feed outletmetering bulk material with a metering mechanism disposed at the blenderinlet; determining, via a controller in communication with the at leastone sensor, a rate of bulk material being routed into the blender inletand through the metering mechanism; and calculating, via the controller,a calibration factor for the metering mechanism based at least in parton a measurement from the at least one sensor.

A thirteenth embodiment, which is a method of the twelfth embodiment,further comprising receiving, at the controller, an indication of a typeof bulk material in at least one of the one or more portable containersas read from an RFID tag associated with the one or more portablecontainers; and calculating the calibration factor for the type of bulkmaterial received read from the RFID tag.

What is claimed is:
 1. A system, comprising: a support structure forholding at least one portable container of bulk material at a positionproximate a blender inlet, wherein the support structure comprises: aframe for receiving and holding the at least one portable containerthereon; wherein the portable container is supported on the frame suchthat the portable container is selectively removable from the frame andreplaceable by another portable container; and a choke-feed outletcoupled to the frame for routing the bulk material from the at least oneportable container directly into the blender inlet; at least one sensordisposed in a position to sense an amount of bulk material in the atleast one portable container; a metering mechanism disposed at theblender inlet; and a controller in communication with the at least onesensor programmed to determine a rate of bulk material being routed intothe blender inlet and through the metering mechanism, wherein thecontroller is programmed to adjust its control of the metering mechanismbased on the rate of bulk material being fed into the blender inlet asmeasured by the at least one sensor.
 2. The system of claim 1, whereinthe metering mechanism comprises a sand screw, a metering gate, or ametering valve.
 3. The system of claim 1, wherein the support structureis sized to hold multiple portable containers of bulk material thereon.4. The system of claim 1, wherein the at least one sensor comprises astrain gauge, a piezoelectric gauge, a hydraulic gauge, or a pneumaticgauge.
 5. The system of claim 1, further comprising: a hopper disposedat the blender inlet, wherein an outlet of the hopper is coupled to aninlet of the metering mechanism; and a mixer coupled to an outlet of themetering mechanism.
 6. A system, comprising: a support structure forholding at least one portable container of bulk material at a positionproximate a blender inlet, wherein the support structure comprises: aframe for receiving and holding the at least one portable containerthereon; wherein the portable container is supported on the frame suchthat the portable container is selectively removable from the frame andreplaceable by another portable container; and a choke-feed outletcoupled to the frame for routing the bulk material from the at least oneportable container directly into the blender inlet; at least one sensordisposed in a position to sense an amount of bulk material in the atleast one portable container; a metering mechanism disposed at theblender inlet; and a controller in communication with the at least onesensor programmed to determine a rate of bulk material being routed intothe blender inlet and through the metering mechanism, wherein thecontroller is programmed to: receive an output from a flowmeter coupledto a fluid inlet flow line to a blender unit having the blender inlet;and calculate a concentration of the bulk material in the blender unitbased on the output from the flowmeter and the rate of bulk materialbeing fed into the blender inlet.
 7. The system of claim 6, wherein thecontroller is programmed to control the metering mechanism based on thecalculated concentration of the bulk material in the blender unit. 8.The system of claim 6, further comprising a densometer installed in anoutlet flowline of the blender unit and communicatively coupled to thecontroller, wherein the controller is programmed to compare thecalculated concentration of the bulk material in the blender unit to amaterial concentration measured by the densometer.
 9. The system ofclaim 6, wherein the metering mechanism comprises a sand screw, ametering gate, or a metering valve.
 10. The system of claim 6, whereinthe portable support structure is sized to hold multiple portablecontainers of bulk material thereon.
 11. The system of claim 6, whereinthe at least one sensor comprises a strain gauge, a piezoelectric gauge,a hydraulic gauge, or a pneumatic gauge.
 12. A method, comprising:receiving and holding one or more portable containers of bulk materialonto a frame of a support structure disposed proximate a blender inlet,and wherein the portable container is supported on the frame such thatthe portable container is selectively removable from the frame andreplaceable by another portable container; sensing an amount of bulkmaterial in the one or more portable containers via at least one sensor;routing bulk material from the one or more portable containers directlyinto the blender inlet via a choke-feed outlet; metering bulk materialwith a metering mechanism disposed at the blender inlet; determining,via a controller in communication with the at least one sensor, a rateof bulk material being routed into the blender inlet and through themetering mechanism; and calculating, via the controller, a calibrationfactor for the metering mechanism based at least in part on ameasurement from the at least one sensor.
 13. The method of claim 12,further comprising: receiving, at the controller, an indication of atype of bulk material in at least one of the one or more portablecontainers as read from an RFID tag associated with the one or moreportable containers; and calculating the calibration factor for the typeof bulk material received read from the RFID tag.
 14. The method ofclaim 12, further comprising metering bulk material from the blenderinlet into an inlet of a mixing chamber via the metering mechanism. 15.The method of claim 12, further comprising monitoring changes in thecalibration factor over time.
 16. The method of claim 15, furthercomprising determining when the metering mechanism needs to be replacedbased on a trend of the calibration factor changing over time.
 17. Themethod of claim 16, further comprising outputting a warning upondetermining that the metering mechanism needs to be replaced.
 18. Themethod of claim 12, further comprising performing a fracture treatment,a diversion, or a cement mixing operation using a blender unit havingthe blender inlet.
 19. A method, comprising: receiving and holding oneor more portable containers of bulk material onto a frame of a supportstructure disposed proximate a blender inlet, and wherein the portablecontainer is supported on the frame such that the portable container isselectively removable from the frame and replaceable by another portablecontainer; sensing an amount of bulk material in the one or moreportable containers via at least one sensor; routing bulk material fromthe one or more portable containers directly into the blender inlet viaa choke-feed outlet; metering bulk material with a metering mechanismdisposed at the blender inlet; and comparing the amount of bulk materialsensed to be in the one or more portable containers received on theframe of the support structure to an amount of bulk material recorded ona weight ticket or on an RFID tag associated with the one or moreportable containers.
 20. A method, comprising: receiving and holding oneor more portable containers of bulk material onto a frame of a supportstructure disposed proximate a blender inlet, and wherein the portablecontainer is supported on the frame such that the portable container isselectively removable from the frame and replaceable by another portablecontainer; sensing an amount of bulk material in the one or moreportable containers via at least one sensor; routing bulk material fromthe one or more portable containers directly into the blender inlet viaa choke-feed outlet; metering bulk material with a metering mechanismdisposed at the blender inlet; and determining an amount of bulkmaterial remaining in one or more portable containers that are partiallyemptied based on measurements from the at least one sensor.